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Related Manuals for State Water Heaters STC-080
Summary of Contents for State Water Heaters STC-080
- Page 1 SERVICE HANDBOOK STANDARD RESIDENTIAL GAS WATER HEATERS Printed in the USA 0604 $15.00 This service handbook addresses service issues associated with Standard Residential Gas Water Heaters. Includes C-3 Flammable Vapor Technology. (NON POWER VENTED MODELS) Part Number STC-080...
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Page 2: Table Of Contents
RESIDENTIAL GAS, NON POWER VENTED, WATER HEATER Introduction Terms... 1 Tools ... 2 Residential Gas Water Heaters Guidelines... 3 Installation... 5 Operations and Servicing Construction... 6 Control ... 6 Burner ... 7 Normal Operations ... 7 Temperature ... 8 Gas ... 8 Water Flow... -
Page 3: Tools
RESIDENTIAL GAS, NON POWER VENTED, WATER HEATER Tools Required: Phillips head screw driver • 3/8, 7/16, ¾ inch open end wrenches • 3/16 inch Allen wrench • 11/16 inch – 6 point – socket – for anode removal • set of marked drill bits •... -
Page 4: Residential Gas Water Heaters Guidelines
RESIDENTIAL GAS, NON POWER VENTED, WATER HEATER Water Hammer – is a concussion of moving water against the sides of a containing pipe or vessel on a sudden stoppage of flow. EX: 1/2 “copper pipe, 5GPM flow (7.2ft/sec.) – stop. Pressure rise of approximately 412 PSI. 3/4”... - Page 5 RESIDENTIAL GAS, NON POWER VENTED, WATER HEATER SERVICE HANDBOOK Centimeters = Inches X 2.54 MM (millimeters) = Inches X 25.4 Meters = Inches X .0254 Doubling the diameter of a pipe will increase its flow capacity (approximately) 5.3 times. CONSTRUCTION: Tank is constructed of steel.
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Page 6: Guidelines
RESIDENTIAL GAS, NON POWER VENTED, WATER HEATER INSTALLATION OF RESIDENTIAL GAS WATER HEATER Union See Manual and Labels For Installation Clearances Typical Model and Rating Plate Location Maximum Gas Supply 13.8” W.C. or ½ PSI Minimum 4.5” W.C. –Natural Gas 11.0”... -
Page 7: Operations And Servicing Construction
RESIDENTIAL GAS, NON POWER VENTED, WATER HEATER RESIDENTAL GAS WATER HEATER SERVICE This portion of this manual applies to the Operations and Servicing of Residential Gas, Tank Type, Water Heaters, which are vented atmospherically and use a thermocouple as their electrical source. -
Page 8: Burner
RESIDENTIAL GAS, NON POWER VENTED, WATER HEATER SERVICE HANDBOOK Residential Gas – continued Burner: The burner assembly consists of the main burner, main burner orifice, main burner gas supply tube, pilot burner, pilot burner orifice, pilot burner gas supply tube and thermocouple. The pilot burner remains on once it is manually lit. -
Page 9: Temperature
RESIDENTIAL GAS, NON POWER VENTED, WATER HEATER SERVICE HANDBOOK Residential Gas – continued Temperature: Two metal probes mounted onto the back of the control are immersed inside the tank water. One probe (the shorter) acts as a temperature high limit. If water gets excessively hot, a sensor within the probe opens, interrupts the small electrical current to the gas valve, and gas... -
Page 10: Water Flow
RESIDENTIAL GAS, NON POWER VENTED, WATER HEATER Residential Gas - continued Water Flow: When a hot water faucet is opened, water pressure from the well tank or street main forces cold water into the water heater. This pushes hot water out of the tank. Operation: A residential water heater is not a precise operating appliance. -
Page 11: Service
RESIDENTIAL GAS, NON POWER VENTED, WATER HEATER Residential Gas - continued Service: Air: A gas burning appliance requires the oxygen contained in 12.5 cubic feet of air (at sea level) for every 1000 BTU of heat that is generated. If your water heater has a BTU per hour input of 40,000 BTU then a minimum of 500 (40 times 12.5) cubic feet of clean air must be available. - Page 12 RESIDENTIAL GAS, NON POWER VENTED, WATER HEATER • Possible carbon monoxide • Smell of burnt gas in the room Residential Gas – continued The instruction manual gives guidelines under “Air Requirements” and “Unconfined “ or “Confined Space” sections. If you want to test for a lack of air: 1.
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Page 13: Procedures And Conditions
RESIDENTIAL GAS, NON POWER VENTED, WATER HEATER Residential Gas - continued Sooting causes If … the burner is clean but the chamber and/or flue are sooted the main burner, chamber and flue are sooted Electrical Testing This type of water heater has its own electrical generating system. - Page 14 RESIDENTIAL GAS, NON POWER VENTED, WATER HEATER Residential Gas - continued Electrical Testing– continued Millivolt dropout test through copper magnet winding and ECO (Emergency Cut Off) Procedure: Move meter probe to upper ECO solder joint and ground If … reading of at least 10 mV is not present reading of more than 10 mV is present but, gas to the pilot shuts off each time knob is released...
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Page 15: Multiple Heater Piping
RESIDENTIAL GAS, NON POWER VENTED, WATER HEATER Residential Gas – continued Condensation is a mild acid – it will corrode steel Condensation is usually noted when: • water dripping is heard (only) while the main burner is on, • there is “water” around the heater just after the heater has been operating, •... -
Page 16: Construction
RESIDENTIAL GAS, NON POWER VENTED, WATER HEATER Residential Gas – continued Exhaust Venting Notes Follow current National Fuel Gas Code requirements for proper installation. FLAMMABLE VAPOR IGNITION RESISTANT (FVIR) DESIGN This section will address the changes brought about by the introduction of FVIR compliant products. -
Page 17: Lint, Dust & Oil Screen
RESIDENTIAL GAS, NON POWER VENTED, WATER HEATER IMPLEMENTATION ANTICIPATED CATEGORY INTRODUCTION July 1, 2003 Phase I (July 1, 2004* Can.) Phase II January 1, 2005* Phase III July 1, 2005* * Subject to change. This supplement addresses the July1, 2003 compliant products. In addition to the standard water heater design discussed in the main service handbook, the C3 Technology design also includes: •... -
Page 18: Flame Arrestor
RESIDENTIAL GAS, NON POWER VENTED, WATER HEATER Made from Corderite, a fireproof ceramic material, the flame arrestor is built into the base of the water heater. Combustion air is drawn in through the LDO screen (s). After entering the bottom area of the water heater, this air passes up through the small ports of the flame arrestor and into the combustion chamber. -
Page 19: Thermal Cut Off Switch
RESIDENTIAL GAS, NON POWER VENTED, WATER HEATER If there has been a flammable vapor ignition, a qualified service agent needs to inspect the arrestor for cracks. The arrestor is not a replaceable part – the heater would need to be replaced. Possible service issues associated with the flame arrestor. -
Page 20: Pilot Burner Assembly
RESIDENTIAL GAS, NON POWER VENTED, WATER HEATER SERVICE: There is no routine service associated with the TCO. The standard thermocouple millivolt output checks described in this service handbook still apply. Millivolt readings indicate that the TCO is closed. An open TCO (within a cool chamber) would indicate that the assembly must be replaced. -
Page 21: Sealed Combustion Chamber
RESIDENTIAL GAS, NON POWER VENTED, WATER HEATER Turn off the gas supply Disconnect the piezo cable from the piezo button (connection near gas control valve). Disconnect the pilot tubing, thermocouple and main burner tube from the bottom of the gas control valve. Remove (2) 3/8 inch nuts securing the inner door. - Page 22 RESIDENTIAL GAS, NON POWER VENTED, WATER HEATER The three seals on the inner door should be checked every time any service is performed. The sight glass should be checked to insure it is not damaged or missing. The pilot tube and thermocouple routing should be straight (not bent at an angle close to the surface of the seal) as it passes through the pilot assembly seal.
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Page 23: Piezo Igniter
RESIDENTIAL GAS, NON POWER VENTED, WATER HEATER SERVICE HANDBOOK PIEZO IGNITER C3 TECHNOLOGY models will feature a Piezo igniter to light the pilot burner. The push button switch will be located on the top of the gas control valve. There will be a plug connector between the push button and the igniter wire which is part of the pilot burner assembly. - Page 24 RESIDENTIAL GAS, NON POWER VENTED, WATER HEATER WHY WATER HEATER TANKS LEAK WHAT Water Water expands when it is heated Pressure (Thermal Expansion). Water cannot be compressed. Excessive Pressure in the tank causes failure of joints, welds or gaskets. Condensation) Products of combustion contain moisture.
- Page 25 RESIDENTIAL GAS, NON POWER VENTED, WATER HEATER WHY WATER HEATER TANKS LEAK - WATER CONDITIONS WHAT “Hard” Water “Hard” water contains minerals. As water is heated the minerals separate from the water and attach to hot surfaces within the tank. In gas water heaters, these minerals “insulate”...
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Page 26: Technical Bulletins
RESIDENTIAL GAS, NON POWER VENTED, WATER HEATER TECHNICAL BULLETIN - 11 Water hammer is the destructive forces, pounding noises and vibration in a piping GENERAL system when water flowing through a pipeline is stopped abruptly. When water hammer occurs, a high intensity pressure wave travels back through the piping system until it reaches a point of some relief. - Page 27 RESIDENTIAL GAS, NON POWER VENTED, WATER HEATER TECHNICAL BULLETIN - 13 • Rumbling SYMPTOMS With the advent of high input and larger storage tanks in both commercial and CAUSE residential heaters, deliming has become a necessity of modern maintenance. Lime (CaCO ), is the most notable factor when discussing water hardness.
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Page 28: Aluminum Hydroxide
RESIDENTIAL GAS, NON POWER VENTED, WATER HEATER TECHNICAL BULLETIN - 14 “Crackling”, “gurgling”, or “popping” noises from new water heaters (installed less than SYMPTOMS six months). In a few isolated parts of the United States where the water supply has a relatively high pH (8+), CAUSE water conditions will react with the aluminum anode to form excessive amounts of aluminum hydroxide on the anode and in the bottom of the tank. -
Page 29: Discolored Water
RESIDENTIAL GAS, NON POWER VENTED, WATER HEATER TECHNICAL BULLETIN - 21 Rusty, brown, black, or yellow water appearing in the hot water. SYMPTOMS Complaints of discolored water are commonly blamed on water heaters and CAUSE storage tanks, but in fact, it is a rare occurrence for today’s high quality glass lined tanks to have a lining failure significant enough to allow water to contact enough bare metal to discolor the contents of even a small tank. -
Page 30: Smelly Water
RESIDENTIAL GAS, NON POWER VENTED, WATER HEATER TECHNICAL BULLETIN - 22 The most common cause of “smelly water” is a non-toxic sulfate reducing CAUSE bacteria, scientifically termed Divibrio Sulfurcans. This bacterium often enters the water system through construction or a break in ground piping. The bacteria create the energy it needs to survive by converting sulfate (SO hydrogen sulfide (H Hydrogen sulfide gas is distinctive because of its rotten egg-like stench. - Page 31 RESIDENTIAL GAS, NON POWER VENTED, WATER HEATER TECHNICAL BULLETIN - 23 CHLORINATION PROCEDURE The chlorination procedure is used to eliminate various bacteria that CAUSE accumulate and grow in water heaters. These bacteria often cause odorous or discolored water conditions. Please read the steps of the chlorination procedure prior to beginning. If you PROCEDURE feel uncomfortable performing any of these steps, contact a service person to perform this procedure for you.
- Page 32 RESIDENTIAL GAS, NON POWER VENTED, WATER HEATER TECHNICAL BULLETIN - 35 NOT ENOUGH HOT WATER - GAS Not enough hot water complaints are becoming more frequent in the water heater CAUSE industry. This increase was triggered when changes required by our regulatory agencies were implemented.
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Page 33: Thermal Expansion
RESIDENTIAL GAS, NON POWER VENTED, WATER HEATER TECHNICAL BULLETIN - 45 • Effects are only noticeable after hot water use followed by periods of no water use. SYMPTOMS • Relief valve drips during any recovery cycle when no hot or cold water is used. •... - Page 34 RESIDENTIAL GAS, NON POWER VENTED, WATER HEATER The ideal fix involves the use of a pressure reducing valve if supply pressures are THE FIX above 60 to 70 psi, and a properly sized expansion tank. The PRV reduces supply pressures to 40 to 60 psi allowing an economically priced and sized expansion tank to be used.
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Page 35: Leaking Temperature And Pressure Relief Valve
RESIDENTIAL GAS, NON POWER VENTED, WATER HEATER TECHNICAL BULLETIN - 52 LEAKING TEMPERATURE AND PRESSURE RELIEF VALVE • Water seeping around the relief valve tank connection SYMPTOMS • Leakage at the threaded portion of the relief valve connection • Intermittent weeping and/or dribbling from the relief valve •... - Page 36 To order additional copies of this Service Handbook and to view other service and presentation literature and CDs that are available from State Water Heaters: Telephone 1-800-821-2017, Fax number 800-644-9306 or visit our web site at www.statewaterheaters.com For additional information or assistance in servicing you’re State water heater, visit our web site or telephone the Technical Information Department at 1-800-365-0024 This Service Handbook was prepared by the Technical Training Department,...